Apparatus for making tile panels



Patented Oct. 14, 1958 APPARATUS rou MAKING TILE PANELS Ernest L.Kastenbein, Rutherford, N. 1., assignor, by mesne assignments, to TileCouncil of America, Incorporated, a corporation of New York ApplicationOctober 7, 1955, Serial No. 539,196

12 Claims. (Cl. 25-1) The present invention relates to the fabricationof multiple elements or mosaic type objects and more particularly to themanufacture of multiple tile panels.

The use of prefabricated multiple tile panels offers a number ofadvantages which are not generally obtained by the construction of tilewalls at their final location. Panels may be quickly installed.Prefabrication allows uniform spacing of the tile in the panel Whichmakes the panel attractive.

In the co-pending application of John V. Fitzgerald, entitled CeramicTile Panels and Structural Members, Serial No. 471,748, filed November29, 1954, there was shown and described various forms of ceramic tilepanels consisting, of a plurality of ceramic tiles positioned edge toedge. Such panels of the type shown and described in the applicationreferred to immediately above provide a type of panel which lends itselfto prefabrication.

A primary object of this invention is to provide improved apparatus forthe fabrication of multiple tile panels.

It is another object of this invention to provide apparatus for themanufacture of tile panels which enables the operator to convenientlyinsert the grout between the tiles during the process of fabrication ofthe panel.

It is still another object of this invention to provide improvedapparatus for the manufacture of tile panels and the like wherein thegrout bonding the tiles will present a concave surface on the finishedside of the panel.

According to this invention there is provided apparatus for theconstruction of multiple tile panels and the like in which a cushion isadapted to receive a plurality of tiles positioned edge to edge withfinished side toward the cushion. Under each tile there is provided acavity in the cushion which is arranged to be evacuated so as to causethe atmospheric pressure to force the tiles into the cushion in such amanner that the cushion material will bulge between the tiles thusforming a concave surface on the grout between the tiles. The pressureof the tiles against the cushion will also seal the joint be tween theedge of the tiles and the cushion so that there will be no feather edgeof the grout over the glazed surface of the tile.

Other and incidental objects of the invention will become apparent aftera reading of the following specifications and an inspection of theaccompanying drawings wherein:

Figure 1 illustrates one form of this invention.

Figure 2 illustrates a cross section of the vacuum table of one form ofthis invention.

Figure 3 shows an enlarged cross section of one form of this invention,and

Figure 4 illustrates in detail still another form of this invention.

Throughout the various figures of the drawing the same numeral will beemployed to designate the same element. Turning now in more detail toFigure 1 there is shown the rigid support member or table top 11supporting a cushion or other resilient member 13 upon which are placeda plurality of tiles 15 positioned edge to edge with finished surfacedownward. The tiles 15 are arranged so that there is a groove 17 betweeneach of the tiles. Groove 17 is intended to be filled with grout inliquid form which is then allowed to set. Strips of 22 gauge metal maybe used to properly space the tiles 15. The metal strips are removedbefore the grout is applied.

Many different types of mortars have been previously used for groutingtile. Typical of these mortars have been those consisting essentially ofPortland cement. An improved mortar for grouting tile is described in acopending application of John V. Fitzgerald, entitled Dr'y Mortar MixComprising Portland Cement and Polyvinyl Acetate, Serial No. 471,910,filed November 29, 19 54.

In order to cause the cushion 13 to bulge into the grooves 17 betweenthe tiles to form a concave grout surface and to seal the bottom of thegrooves 17 to prevent the grout from feathering out onto the surface ofthe tiles, pressure must be applied to cause the tiles to compress thecushion 13.

According to this invention the atmospheric air pressure is used topress the tiles 15 against the cushion 13. This is accomplished byevacuating the cavity under each of the tiles.

Figure 2 shows in detail one form of the invention wherein thesupportmember 11 is provided with a cushion 13 supporting tiles 15. It will beseen from an inspection of Figure 2 that air cavities 19 are provided inthe cushion 13. The air cavities 19 are operably connected to a vacuumpump 21 by pipes 23.

When all of the tiles 15 have been arranged properly on cushion 13 andspaced to provide the desired grooves 17 the vacuum pump 21 is startedand the cavities 19 are evacuated. Upon evacuation of cavities 19 theatmospheric pressure will cause tiles 15 to compress the cushion 13. Itis important to note, however, that the cushion 13 will bulge into thegrooves 17 causing little bumps in each of the grooves 17.

Cushion 13 may consist of firm foam rubber, one inch thick. The uppersurface of the cushion 13 should have a smooth surface. When the oneinch thick foam rubber is employed 28 inches of vacuum has proven verysatisfactory.

Cushion 13 may also be molded in such a manner that it has ridges underall the grooves 17 between the tiles 15. Molded cushions permit the useof lower vacuum to provide the necessary seal between the cushion 13 andthe tiles 15.

By the use of a suitable air valve in connection with the vacuum pump 21a predetermined degree of partial vacuum may be maintained in cavities19. A suitable grout may then be poured into grooves 17 and allowed toset while the partial vacuum is maintained in cavities 19.

The bulging of the cushion 13 into the groove 17 will cause the bottomof the grooves to take a concave curvature thus properly forming thegrout on the face of the tile panel which is positioned against thecushion. The pressure of the tile on the cushion is sufficient to sealthe bottom corners of the grooves 17 and thus prevent the grout fromleaking to the area between the tile 15 and the cushion 13. The finishedsurface of the tile may be coated with an agent to prevent wetting ofthe glazed surface of the tile by the grout. An agent such as siliconeoil may be employed for this. purpose.

When the grout in grooves 17 has thoroughly set the vacuum is removedfrom the cavities 19. This permits the panel to be lifted from theapparatus.

Turning now to Figure 3, there is shown still another form of thisinvention wherein the rigid support member takes the form .of a vacuumchamber 25 which supports the cushion 13. The top of the vacuum chamber25 is provided with holes 27 one of which is located beneath each of thetiles 15.

The vacuum chamber 25 may have support members 29 to prevent collapse ofthevacuum chamber 25 due to air pressure.

The operation of the form of the invention shown in 'Figure 3 is similarto-the operation of the form of the invention described above.

.Turning now in detail to Figure 4, a cut away view shows ;a vacuumchamber 25 as described in connection with Figure 3. The vacuum chamber25 supports a cushion 1-3 over which is spread an air proof membrane 31in which there have been .cut small holes 33 whose positions correspondwith holes 27 in the upper section of the vacuum chamber 25. Tiles 15are positioned as shown and described in connection with Figures 1, 2,and 3.

The membrane may be polyethelene film 1 to mils thick or anothermaterialhaving similar properties.

The purpose of the air proof membrane 31 as illustrated in Figure 4 isto provide an improved air seal under the tiles 15. Membrane 31 allowsthe use of a cushion such as foam rubber which is air permeable. Themembrane 31 insures a smooth surface for the grout.

By employing air pressure to compress the tiles into thecushion memberit will be seen thatno framework is necessary on the top of the machine.The operator, therefore, is not impeded in'poun'ng the grout into thegrooves between the tiles by'framework or other apparatus. The operatorstime in the fabrication of the tile panel is therefore reduced "to aminimum and careful adjustment of complicated mechanical devices forexerting pressure is not necessary. Due to the uniformity of atmosphericpressure over the surface of the machine each of'the' tiles is subjectedto the same amount of pressure. The fabricated tile panel will thereforepresent a uniform surface.

Having thus described the invention,'what is claimed is:

1. Apparatus for holding tiles in position while the grout is setting inthe grooves between the tiles during the fabrication of a tile panel,said apparatus comprising a cushion, said cushion adapted to receive aplurality of tiles .in a prearranged 'spacedposition and with a finishedsurface toward said cushion, a cavity in said cushion under each of saidtiles, means for developing a partial vacuum, and means operativelyconnecting said partial vacuum developing means to each of said cavitiesto cause a partial vacuum in the cavities under the tiles whereby airpressure will push saidtiles into the cushion, causing the cushion tobulge into the grooves between the tiles whereby there is formed aconcave surface on the grout in the grooves of'the tile panel.

' 2. The invention as set forth in claim 1 and wherein said cushion isof sponge rubber.

.3. The invention asset forth in claim 1 and wherein an air proofmembrane is positioned between said cushion and said tiles, there beinga hole through said membrane under each tile.

4. Apparatus for holding mosaic elements in position during the settingof a bonding agent in the grooves between the mosaic elements during thefabrication of a mosaic, said apparatus comprising a cushion, saidcushion adapted to receive said mosaic elements in desired spacedposition and with a finished surface toward said cushion, a cavity insaid cushion under each of said mosaic ele ments, and means fordeveloping a partial vacuum in said cavities to cause the cushion tobulge into the grooves between said mosaic elements whereby the bondingagent in the grooves between the mosaic elements will have a concavecurvature on the finished surface of the mosaic.

' 5. Apparatus for holding tiles 'in' position during setting of.grout'tofabricate .tilepanels, said apparatus comprising in'combination a rigid :support member, a cushion covering'saidrigid'support member, said cushion adapted to receive a plurality oftiles positioned edge to edge and having a finished surface toward saidcushion, a hole in said cushion under each of said tiles, and means fordeveloping a partial vacuum in each hole in the cushion to cause saidcushion to bulge into the groove between the tiles whereby the surfaceof the grout on the finished surface of the panel has a concavecurvature.

6. Apparatus for making panels of tile, said apparatus comprising arigid support member adapted to support a plurality of said tile on itsupper surface, said tiles positioned edge to edge and separated fromeach other by spaces to form grooves between the tiles, a flexibleelement distributed on the surface of said rigid support member undersaid grooves and under the edges of said tile, means for developing apartial vacuum between said rigid support member and said tiles to causesaid flexible element to form a convex surface in the bottom of saidgrooves whereby a liquid bonding agent poured into said grooves willhave a concave surface at the bottom of said grooves.

7. The invention according to claim 1 and wherein said means fordeveloping a partial vacuum between said rigid suport member and saidtile consists of a vacuum chamber under said rigid support member and aseries of holes connecting said vacuum chamber with the area under eachof the tiles.

8. The invention according to claim 1 and wherein said means fordeveloping a partial vacuum between said rigid support member and saidtile consists of a vacuum pump and a hole in said support member undereach of the tiles.

9. Apparatus for makingpanels of a plurality of elements comprising thecombination of a rigid support member adapted to receive a plurality ofsaid elements on its surface, said elements spaced from each other toform grooves between said elements, a resilient member distributed oversaid rigid support member and under said grooves, means for developing apartial vacuum between each of said elements and said rigid supportmember to hold said elements in position and form a convex surface inthe bottom of said grooves between said elements, and wherein saidgrooves are adapted to receive a bond ing agent.

10. Apparatus for making tile panels comprising a vacuum chamber, asurface of said vacuum chamber adapted to receive tile, the finishedsurface of said tile positioned toward said vacuum chamber, a grill workof resilient material positioned under the grooves between the tile, ahole'in said vacuum chamber under each of said tiles whereby theresilient material is caused to bulge into the grooves between the tilesto form a convex surface in the bottom of the grooves between the tiles,and grout filling said grooves to bond said tile together to form apanel.

11. Apparatus for making panels from tiles comprising in combination asupport member, said support member adapted to receive a plurality oftiles positioned edge to edge with space between each tile and with thefinished surface toward said support member, a resilient memberdistributed on the surface of said support member under the groovesbetween said tiles, means for developing a partial vacuum, meansconnecting said vacuum developing means to the space under each tile tocausesaid tile to compress said resilient member, thus causing theresilient member to bulge into the grooves between the tile and form aconvex surface in'the bottom of the grooves, whereby grout allowed toset in the grooves between the tiles will have a concave surface.

12. Apparatus for making tile panels and the like comprising incombination a rigid support member, said rigid support member adapted toreceive a plurality of tile positioned edge to edge, finished surfacedown, and spaced from each other so as to form grooves between thetiles; a pad of compressible material between said rigid support memberand said tile, said pad extending between said tiles; means fordeveloping a partial vacuum References Cited in the file of this patentbetween said rigid support naember and each of said tiles UNITED STATESPATENTS to cause sa1d pad to bulge into the grooves between sa1d tiles;and means for applying a bonding agent to said 2266; 10 Pmtmger 1941grooves whereby the surface of said bonding agent be- 5 2,443,987Morrison June 1948 tween the finished surfaces of the tile will beconcave 2,513,785 Browne July 1950 2,517,701 Oettlnger Aug. 8, 1950 whenset.

